User Manual Floor Scrubber Disc Brush Drive
This manual is furnished with each new Floor Scrubber. This provides the necessary operating and preventive maintenance instructions. Operators must read and understand this manual before operating or servicing this machine. This machine was designed to give you excellent performance and efficiency. For best results and minimal cost, please follow the general guidelines below: Operate the machine with reasonable care. Follow the manufacturer s suggested maintenance instructions as provided in this booklet. Use original PowerBoss supplied parts. 2
Technical Specifications Model Model No. Floor Scrubber Brush Drive E20BDQP-FC, E20BDQPG-FC Current (Max) Battery Capacity (Lead Acid) Battery Capacity (Gel) Sound Level Cleaning path width Squeegee width Theoretical productivity Working speed Rated voltage Vacuum flow Vacuum waterlift Vacuum power Brush type Brush motor(s) power Number of brushes Brush RPM Aqua-Stop equipped Solution capacity Recovery capacity Working Grade Weight with batteries Weight without batteries Dimensions (LxWxH) 32 amps 105Ah @20 hr 95Ah @20 hr 69 dba 20 in (51 cm) 34 in (86 cm) 15,000 ft 2 /hr ( 1,394 m 2 ) 1.7 mph (2.7 km per hr) 24 volts 65 cfm (110 m3/hr) 45 inches ( 112mbar).60 HP (450 W) Disc 3/4 HP (560W) 1 180 RPM Coming Soon 12 Gal (45 liters) 13 Gal (49 liters) 2% 313 lbs (142 kg) 203lbs (92 kg) 47.4 x 21.3 x 42.3 (120.4 x 54.1 107.4 cm) 3
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Table Of Contents Technical Specifications... 3 Safety Instructions... 6 Unpacking Instructions... 7 Inspection... 7 Electrical... 7 Batteries... 7 Operator Responsibility... 7 Machine Overview... 8 Machine Overview - Front... 8 Machine Overview - Rear... 9 Control Panel... 10 Bail Handle... 11 Handle Adjustment Knobs... 11 Key Switch... 11 Squeegee Lift Lever... 11 Solution Control Lever... 11 Battery Gauge... 11 Charge Status Indicator... 11 Optional Hour Meter... 12 Optional Solution Solenoid... 13 In-Line Solution Filter Assembly... 13 Battery Compartment... 14 Circuit Breakers... 14 Floor Scrubber Rear Squeegee... 16 Cleaning... 16 Changing... 16 Angle Adjustment... 17 Adjusting the Floor Scrubber Squeegee Blades... 18 Handle Adjustment... 19 Angle Adjustment... 19 Horizontal Adjustment... 20 Solution Tank Drain Hose... 21 Solution Level Indicator... 21 Solution Fill Filter... 22 Screened Float... 23 Screened Float Removal... 24 The Floor Scrubber... 26 Machine Operation... 28 To Turn on Machine... 28 To Turn on Vacuum... 28 To Turn on Brush Motor... 28 To Turn on Cleaning Solution... 28 To Charge Batteries... 28 Hour Meter (Optional)... 29 Solution Solenoid (Optional)... 29 Loading Brush... 30 Unloading Brush... 31 After Use... 34 Maintenance... 35 Troubleshooting... 36 Warranty... 38 5
Safety Instructions IMPORTANT SAFETY INSTRUCTIONS Operators must read and understand this manual before operating or maintaining this machine. Do not operate this machine in flammable or explosive areas. This machine is designed solely for scrubbing dirt and dust in an indoor environment. The manufacturer does not recommend using this machine in any other capacity. The following information below may cause a potential hazard to the operator and equipment. Read this manual carefully and be aware when these conditions can exist. Take necessary steps to locate all safety devices on the machine and train the personnel operating the machine. Report any machine damage or faulty operation immediately. Do not use machine if it is not in proper operating condition. For Safety During Operation Keep hands and feet clear of moving parts while machine is in operation. Make sure all safety devices are in place and operate properly. All covers, doors and latches must be closed and fastened before use. During operation, attention should be paid to other persons in the work area and especially if small children are present. Electric motors and components can cause an explosion when operated near explosive materials or vapor. Do not operate this machine near flammable materials such as solvents, thinners, fuels, grain dust, etc. Store or park this machine on a level surface only. To prevent unauthorized use, machine should be stored or parked with the key removed. This machine is designed for level operation only. Do not operate on ramps or inclines greater than 2%. This machine is not suitable for picking up hazardous dusts. Use caution when moving this machine into areas that are below freezing temperatures. Any water in the tanks or hoses can cause damage to the machine. For Safety when Servicing or Maintaining Machine Stop on level surface. Disconnect the power to the machine by unplugging the red Battery connector located under the recovery tank near the batteries. Avoid moving parts. Do not wear loose jackets, shirts, or sleeves when working on machine. Avoid contact with battery acid. Battery acid can cause burns. When working on or around batteries, wear protective clothing and safety glasses. Remove metal jewelry. Do not lay tools or metal objects on top of batteries. Charging batteries generates explosive gasses. Do not charge batteries when open flames or sparks are present. Do not smoke. Make sure the charger is turned off before disconnecting it from the machine. Charge the batteries in a well-ventilated area with the battery cover removed completely. Do not clean machine with a pressure washer. Authorized personnel must perform repairs and maintenance. Use Minuteman supplied replacement parts. 6 SAVE THESE INSTRUCTIONS
Unpacking Instructions Inspection Carefully unpack and inspect your Floor Scrubber for shipping damage. Follow unpacking instructions on shipping pallet. Each unit has been tested and thoroughly inspected before shipment. Any damage is the responsibility of the delivery carrier who should be notified immediately. Electrical This machine is battery operated and designed to operate on 24 volts DC (2) 12-volt batteries. Batteries The recommended batteries are rated 105Ah WET (Manufacturer s P/N 956712) or 100Ah MAINTENANCE FREE GEL (Manufacturer s P/N 956100). We do not recommend mixing AMP hour capacities. Alternate battery sets can be used if they equal physical size and capacity. If alternate battery sets are used please contact Minuteman for on board charger settings. Operator Responsibility Read this manual carefully before operating this machine. The operator is responsible for taking care of the daily maintenance of the machine to keep it in good working condition. The operator must inform the service mechanic or supervisor when the scheduled maintenance intervals are required as stated in the MAINTENANCE section of this manual. Before starting, familiarize yourself with the machine and its controls (see Machine Overview, Front, Machine Overview, Rear, Control Console diagrams). 7
Machine Overview Machine Overview - Front A B C D E F G H J CUP HOLDER SOLUTION FILL PORT RECOVERY TANK LID RECOVERY TANK BRUSH DECK FRONT WHEEL REAR CASTER SOLUTION TANK FLOATING DECK SKIRT 8
Machine Overview Machine Overview - Rear I A B C D E F BAIL HANDLE SQUEEGEE LIFT LEVER SOLUTION CONTROL LEVER RECOVERY TANK DRAIN HOSE ONBOARD CHARGER CORD CIRCUIT BREAKERS G H I J K RECOVERY HOSE CONTROL PANEL SOLUTION TANK DRAIN HOSE / LEVEL INDICATOR BRUSH LIFT PEDAL REAR SQUEEGEE 9
Machine Overview Control Panel A B C D E F G BAIL HANDLE HANDLE ADJUSTMENT KNOB KEY SWITCH SQUEEGEE LIFT LEVER SOLUTION CONTROL LEVER BATTERY GUAGE CHARGE STATUS INDICATOR A C D B E F G 10
Machine Overview Bail Handle (A) When the scrubdeck is lowered to the floor, the bail handle enables the brush motor and moves the machine forward once depressed. This also allows the operator to automatically load the brush when the scrub deck is lowered over the brush. Handle Adjustment Knobs (B) Allows the handle position to be raised or lowered. Key Switch (C) Controls the machine s power (Brush Unload/Off/On) with a key for safety. This switch, when turned counter clockwise, operates the auto brush unload when scrubdeck is in the raised position. When it is turned to the ON position, the machine will operate. Squeegee Lift Lever (D) When actuated to the top position, the squeegee is lowered and the vacuum motor turns on. When locked in the bottom position, the squeegee is raised and the vacumm motor shuts off. Solution Control Lever (E) This lever controls the rate at which solution is dispensed. Moving the lever up will increase the amount of solution. Moving the lever down will decrease the solution rate. Moving the lever all the way down shuts off solution flow. Battery Gauge (F) This gauge displays the remaining battery charge. Charge Status Indicator (G) This gauge displays the status of the batteries during charging. The gauge has a readout of 3 LEDs. 1 Green, 1 yellow, 1 Red. Green indicating a full charge, Yellow indicating 80% charged, Red indicating the batteries are charging. 11
Machine Overview Optional Hour Meter The manufacturer offers an optional hour meter for the Floor Scrubber. The optional kit replaces the power cord mounting bracket at the rear of the machine with one that contains an hour meter. Kit# K-E1720HM Optional Pump Kit The Manufacturer offers an optional pump kit for the Floor Scrubber. The pump will turn on when the switch is toggled to the ON position. The hose to coupler fills, then the pump shuts off until the wand (not supplied) is connected and chemical is dispensed. TOGGLE SWITCH Kit# K-E1720P PUMP 12
Machine Overview Optional Solution Solenoid The Manufacturer offers an optional solution solenoid for the Floor Scrubber. The optional solenoid automatically turns off the solution flow when the brush motor is not active. In-Line Solution Filter Assembly Kit# K-E1720S The optional solution solenoid, which shuts off solution flow when the bail handle is released, is protected from debris by the in-line filter assembly. The filter assembly is located at the rear of the machine on the left hand side, just under the solution tank. It is important to check and clean the screened washer inside the assembly regularly to ensure proper solution flow. To open, unscrew the assembly (Note that the cone of the washer is facing out toward the rear of the machine). Remove washer and rinse, reinsert and screw assembly together, tightening by hand. Overtightening with tools may damage the plastic threads. A B C D Fitting, MGHT Screened Washer Hose Barb Insert Fitting, FGHT A B C D 13
Machine Overview Circuit Breakers The circuit breaker is located at the bottom of the back panel of the machine. A B C Main Control Breaker - 4A Brush Motor Breaker - 30A Vacuum Motor Breaker - 20A If any of the functions above are not operating, check if the circuit breaker buttons have tripped. Press to reset. A B C Battery Compartment The battery compartment is located under the recovery tank. The Battery compartment can be accessed for servicing and maintenance by tilting the recovery tank (make sure recovery tank has been drained before tilting). The battery compartment contains two 12-volt batteries connected in series. Connect the batteries according to the battery connection diagram (see diagram). The recommended batteries are 105Ah (Manufacturer s P/N 956712) or 100Ah (Manufacturer s P/N 956100) Gel. The battery tray may be drained if neccessary using the orange drain hose located above the rear caster on the right side of the machine. 14
Machine Overview 15
Machine Overview Floor Scrubber Rear Squeegee A Squeegee B Star-shaped knob C Adjusting screw for angle adjustment D Suction hose E Blade fastening latch F Washers for caster height adjustment G Caster Wheel Axle Cleaning the Floor Scrubber Squeegee Check the squeegee (A) daily and clean as necessary. 1. Pull off the suction hose (D). 2. loosen the two star-shaped knobs (B). 3. Remove the squeegee (A). Changing the Floor Scrubber Squeegee Blades Check the inner and outer squeegee blades on the squeegee (A) weekly for signs of wear. The squeegee blades can be reused by turning them (can be turned for 4 total uses). 1. Pull off the suction hose (D), loosen the two starshaped knobs (B) and remove the squeegee. 2. Unlock the fastening device (E) and remove the outer squeegee blade. Turn the squeegee blade or install a new one, as necessary. Change the inner squeegee blade in the same way. 16
Machine Overview Adjusting the Floor Scrubber Squeegee Blades Angle Adjustment The angle adjustment is the decisive factor in ensuring that the squeegee blades on the squeegee lie evenly on the floor. 1. Park the machine on a level surface and lower the squeegee. 2. Loosen the lower wing nut (B) on the adjusting screw (C) and adjust the squeegee using the adjusting screw so that the ends of the squeegee blades still have contact with the floor. By turning the adjusting screw (C) counterclockwise, the clearance between squeegee blade and floor is increased in the center (Fig. 1). When turning the adjusting screw (C) clockwise, the clearance between squeegee blade and floor is reduced in the center (Fig. 2). 3. Switch the machine on and check the suction pattern. When the machine is in operation, the entire surface of the squeegee blades (center and outer areas) must be applied as evenly as possible. 4. Tighten the lower wing nut (B) on the adjusting screw (C) against the metal bracket to lock in the pitch setting. 1 2 B B A A 17
Machine Overview Adjusting the Floor Scrubber Squeegee Blades Height Adjustment If streaks are present, despite an optimum angle adjustment, the clearance between the caster wheels and floor must be adjusted by changing the number of washers underneath the bracket that holds the wheel. The squeegee height is preset at the factory to 3mm. 3 mm 2 mm 4 mm In cases of very smooth floors, e.g. finished floors, PVC, linoleum, etc., see 2mm illustration for washer configuration. In cases of very uneven floors, e.g. poorly laid tiles (water does not run off), configure as shown in 4mm illustration. Keep the extra washers by installing them above the bracket as shown. 18
Machine Overview Handle Adjustment The Floor Scrubber handle was designed with operator comfort in mind. The angle and horizontal position of the handle can be adjusted to suit the needs of the operator. Angle Adjustment The handle angle can be adjusted without tools by loosening the Angle Adjustment Knob (A) on each side and rotating the handle to the desired position. There are 5 angular positions 11.25 apart for a total of 45 between the minimum and maximum position. A 19
Machine Overview Horizontal Adjustment The horizontal position can be adjusted by removing the 4 Mounting Bolts (B) (2 each side) with a 9/16 socket and sliding the Mounting Plate (P) to one of the 3 available positions. The machine is shipped from the factory in position 1. 3 2 1 P B 20 Plate Position 3 (Fully Extended) Plate Position 2 Plate Position 1 (Shipping Position)
Machine Overview Solution Tank Drain Hose The solution tank may be drained by removing the Solution Tank Drain Hose (A) from the Hose Barb (B) and routing the hose to a floor drain. A B Solution Level Indicator The Solution Tank Drain Hose also serves as a water level indicator for the solution tank. The amount of water remaining in the solution tank can be seen through the clear drain hose. Level markers molded into the solution tank are positioned at 1/4, 1/2, 3/4, and full levels. 21
Machine Overview Solution Fill Filter The Solution Fill Filter (B) should be cleaned regularly. To remove, simply open the Solution Tank Lid (A) and pull the filter out. A B 22
Machine Overview Screened Float If the recovery tank (C) is overfilled or a large amount of foaming is present, the screened float (B) blocks the vacuum intake inside the tank protecting the vacuum motor and internal electronics from water damage. It is essential to keep the float in working order through regular maintenance. B A The float should be cleaned daily by thoroughly rinsing with a hose. Removal of the screened float is not necessary for daily maintenace. C At least once a month the screened float should be completely removed, cleaned, and checked for any damage to the seal or metal screen. WARNING: Damage to the machine may occur if operated without the screened float properly in place. 23
Machine Overview Screened Float Removal The screened float is positioned between the vacuum manifold (A) and recovery tank (C). The screened float (B) can be accessed by removing the 1.5 bolt (D) and two 1.25 bolts (E) that attach the manifold to the recovery tank using a 7/16 socket. A Vacuum Manifold B Screened Float C Recovery Tank D 1.5 Bolt E 1.25 Bolt (2) F Helical Washer (3) G Flat Washer (3) E D E F G A B 24
Machine Overview Recovery Tank Drain Hose Twist Cap to Open and Drain Twist & Lift cap to clean out large debris Deck Skirt Removal (Do not lower with out brush) CAUTION: Bristles may be damaged if deck is lowered onto floor without brush/pad driver installed. Brush Deck Skirt will ride on the floor in use and float up or down based on amount of pad/ brush remaining. With brush removed & deck raised, Remove skirt for cleaning by pulling forward, then down over the edge of the deck. 25
The Floor Scrubber The Floor Scrubber This machine was designed with total operator comfort and ease of use in mind. All machine components have been designed as a total system to efficiently clean dirty floors. The Floor Scrubber has two available scrub head types and sizes to fit specific applications. Please contact your PowerBoss representative for specific recommendations for the correct scrub head type, size, and brush type and chemical applications. Before using the machine, always perform the following steps to ensure proper machine operation: Check under the machine for leaks. Check the rear squeegee for wear and damage. Check the solution and recovery tank levels. After using the machine, always perform the following steps: Check the battery charge level. Charge batteries if necessary. When charging batteries, extra precaution is required: - Battery acid can cause burns. - When working on or around batteries, always wear protective clothing and safety glasses. - Remove metal jewelry. Do not lay tools or metal objects on top of the batteries. - Charging batteries generate explosive gasses. DO NOT CHARGE BATTERIES WHEN OPEN FLAMES OR SPARKS ARE PRESENT. DO NOT SMOKE. - Charge the batteries in a well-ventilated area. - Fluid levels should be checked before and after charging and maintained at the proper levels. If low, add distilled water until the metal plates are covered. - If the machine is not used for an extended period of time, batteries should be kept fully charged with a boost charge once a week. Check for wire, string, or twine wrapped around the scrub brushes. Check the rear squeegee for wear and damage. Check the rear squeegee suction hose for obstructions. Drain and clean the recovery tank. Check under the machine for leaks. Check the service records to determine maintenance requirements. 26
The Floor Scrubber WARNING! - Be sure you understand the machine controls and their functions. - While on ramps or inclines, avoid sudden stops when tanks are filled. - Avoid abrupt sharp turns. Slow down driving speed when going downhill. 27
Machine Operation To Turn on Machine Turn key to operate position ( I ) To Turn on Vacuum Lower squeegee into operate position, vacuum motor will turn on automatically. To Turn on Brush Motor Move brush lift pedal from the home (down) position to the operating position (up). Depress the operator bail handle. Brush motor will turn on and assist to propel the machine forward. To Turn on Cleaning Solution Move solution lever from closed (down) position up to the desired flow position. NOTE: When you no longer want solution or stop the machine for an extended period of time, you must move the solution lever back to the closed (down) position. Otherwise, solution will continue to flow onto the floor. To Charge Batteries When the battery status indicator reaches the red zone the batteries need to be recharged. Take the machine to a well ventilated area, unwind the battery charger power cord from the electrical box cover and plug into an appropriate power source. After approximately 10 seconds the battery charge status indicator will turn on. Be sure to check the battery water levels as recommended. WARNING: Charging batteries generates explosive gasses. Do not charge batteries when open flames or sparks are present. Do not smoke. Charge the batteries in a well-ventilated area. 28
Machine Operation Hour Meter (Optional) Hour meter will automatically record operating time of the brush motor. Solution Solenoid (Optional) Water solenoid will operate when the brush motor is turned on. The solution lever must be moved to the desired operating position, but does not need to be moved to the closed position when stopping for brief periods. 29
Machine Operation Loading Brush 1. To load the brush, first center the Floor Scrubber brush deck over the scrub brush. 2. Lower the scrub deck by releasing the deck lift pedal. 3. With the key turned on, pull the bail handle to engage the scrub brush onto the scrubdeck. 30
Machine Operation Unloading Brush 1. To unload the brush, first lift the scrub deck by pressing down on the deck lift pedal. Make sure the pedal is in the home position shown below. 2. Momentarily turn the key (1 to 2 seconds) to the Brush Unload position then let the key return to the off (O) position. 3. When done correctly the brush should release from the scrub deck and fall to the floor. CAUTION: Make sure scrub deck is clear of all personnel and obstructions before operating Brush Unload. 31
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After Use After Use 1. When finished scrubbing, lift the scrub deck and turn the solution lever off. Lift the rear squeegee. Move the machine to a service area for daily maintenance and review items that may need service. 2. Empty the solution tank by disconnecting the solution tank drain hose from the barb fitting and routing hose to a drain. Rinse the tank with clean water to prevent any buildup of dried chemicals that could clog the plumbing. 3. Empty and clean the recovery tank by flushing with a hose. Be sure to also clean the float shut off screen. 4. Remove the brush or pad holder and rinse them in warm water and hang to dry. 5. Remove the rear squeegee, rinse with warm water and reinstall after cleaning. 6. Check the maintenance schedule in the next section and perform any required maintenance before storing the machine. 7. Store the machine indoors in a clean dry place. Keep from freezing. Leave solution and recovery tank lids open for ventilation to prevent odor buildup. 8. Turn Key switch OFF (O) and remove key. 34
Maintenance Daily Weekly Monthly Yearly Charge Batteries Check Each Battery Cell(s) Lubrication Grease Fittings Check Carbon Brushes Water Level Check/Clean Tanks Check/Clean brush & Hoses Check/Clean the Brush/Pad Check/Clean the Squeegee Check/Clean Vacuum Shut-Off Float in Recovery Tank deck skirt Check/Clean Solution Filter Have a qualified service technician check the vacuum motor carbon motor brushes once a year or after 300 operating hours. The brush motor and transaxle motor carbon brushes should be checked every 500 hours or once a year. NOTE: Refer to the Service Manual for more detail on maintenance and service repairs. Regularly scheduled lubrication of certain machine parts should be performed to insure trouble-free operation of the machine. Apply a generous amount of grease into the fittings on the rear caster swivel (2) until grease seeps out around the bearings. Apply lubricant or light machine oil to lubricate the: Pivot mounting point of the rear squeegee to the chassis (1) Rear squeegee caster wheel axle (2) 35
Troubleshooting Problem Possible Cause Remedy Worn or torn squeegee blades Rotate or replace blades Recovery tank full Empty recovery tank Recovery tank drain hose leak Secure drain hose cap or replace Poor water pick-up Recovery tank lid gasket leak Replace gasket lid cover properly Debris caught in squeegee Clean squeegee Vacuum hose clogged Remove debris and flush hose Using too much solution Adjust solution control lever Recovery hose to squeegee or recovery Reconnect or replace recovery hose tank disconnected or damaged Worn brush or pad Replace brush or pad Wrong brush or cleaning chemical Consult Manufacturer Debris caught on scrub brush Remove debris Poor scrubbing performance Moving machine too fast Slow down Not using enough solution Adjust solution flow setting Low battery charge Recharge batteries Retaining ring on brush motor shaft not in groove Remove brush hub assembly and slide ring into groove Solution tank empty Fill solution tank Inadequate solution flow or Solution lines, valves, filter clogged Flush lines, and clean solution filter. no solution to the floor Solution Lever in down position Move lever up 36
Troubleshooting Problem Possible Cause Remedy Tripped Control Power circuit breaker Reset breaker Batteries have low charge Recharge batteries Machine does not operate Battery charger operating Unplug battery charger when charge is complete Recovery tank full Empty recovery tank Excessive foaming in recovery tank. Empty recovery tank. Use less or change chemical. Use defoaming agent. Carbon Brushes worn Replace carbon brushes Vacuum switch disconnected Connect wiring Vacuum motor does not turn Tripped vacuum motor circuit breaker Reset breaker on Broken vacuum limit switch Replace switch by squeegee lift lever Squeegee in raised position Lower squeegee Foot pedal not in home position Place pedal in notch Tripped brush motor circuit breaker Reset breaker Broken brush motor switch Replace switch Brush does not unload Damaged brush block or drive hub Replace Retaining ring on brush motor shaft not Remove brush hub assembly and in groove slide ring into groove Warning LED Status RED LED lamp blink once RED LED lamp blink twice Charger Warning Indicators Description Output open circuit or short circuit or reverse polarity connection of charger to battery. Battery voltage is too high (may be connected to wrong voltage battery). Abnormal cycle (may be weak or bad battery) Charging time has safety timed out due to battery problem. 37
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988720UMFC Rev A 12/09